The fabric behind a jersey determines breathability, moisture-wicking, durability, print quality, and comfort. Choose right, and players forget they’re wearing it. Choose wrong, and you’ll fight heat, cling, color bleed, and early pilling. Whether you’re ordering a custom baseball jersey for a local league or placing a bulk order for a school or tournament, understanding fabric basics will save money and headaches.
Core Fabric Types Explained
1) Polyester Mesh (Athletic Mesh)
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What it is: Knit with tiny holes for airflow.
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Why teams love it: Excellent ventilation for hot climates and high-intensity play.
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Typical weight (GSM): ~130–170 GSM (lightweight).
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Best for: Game jerseys, practice tops, youth leagues.
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Printing compatibility: Great for sublimation printing (deep, permanent color), good for screen print and heat transfer.
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Watch for: Lower-grade mesh can snag; confirm anti-pilling specs.
2) Bird’s-Eye Piqué (pique or birdseye)
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What it is: Textured knit that looks like tiny honeycombs or eyes.
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Why it works: Balances breathability, structure, and moisture-wicking.
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Best for: Team uniforms that need a clean, polished look on and off the field.
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Printing: Excellent for sublimation; also supports screen printing and HTV.
3) Interlock Polyester
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What it is: Smooth, double-knit fabric with a soft handfeel and solid opacity.
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Why it works: More coverage than mesh; great drape, fewer show-through issues.
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Best for: Premium custom baseball jersey bodies, fanwear, tournament kits.
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Printing: Sublimation-ready; sharp edges for numbers, names, and small logos.
4) Microfiber & Performance Blends (Poly + Spandex/Elastane)
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What it is: Fine denier yarns with 2–8% stretch for mobility.
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Why it works: Four-way stretch, quick-dry, usually odor-resistant finishes.
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Best for: Fitted or athletic-cut tops, compression layers, women’s/elite teams.
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Printing: Sublimation shines; screen print and HTV also possible.
5) Recycled Polyester (rPET)
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What it is: Polyester made from recycled sources (e.g., bottles).
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Why it works: Lower environmental impact, modern performance finishes.
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GSM: Similar to standard poly; check spec sheets.
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Best for: Organizations with sustainability goals and fan merch capsules.
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Printing: Sublimation-friendly, with the same rich color payoff.
6) Cotton & Cotton-Rich Blends (for Fanwear)
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What it is: Natural fiber; soft and familiar.
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Why it works: Comfortable for spectators and lifestyle tees.
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GSM: ~150–200 GSM for tees.
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Best for: Pre-/post-game merch, not high-sweat competitive play.
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Printing: Screen print and DTG are common; sublimation is not ideal on cotton.
Quick Comparison
| Fabric | Breathability | Stretch | Durability | Print Quality | Best Use Cases |
|---|---|---|---|---|---|
| Mesh Polyester | High | Low–Med | High | Excellent (sublimation) | Game jerseys in heat |
| Bird’s-Eye Piqué | Med–High | Low–Med | High | Excellent | Polished team kits |
| Interlock Poly | Medium | Low–Med | Very High | Excellent | Pro look & opacity |
| Microfiber/Spandex | High | High | High | Excellent | Performance fit |
| Recycled Poly | Med–High | Low–Med | High | Excellent | Eco-forward teams |
| Cotton/Blends | Medium | Low | Medium | Great (non-sublimation) | Fan tees & merch |
The Specs that Matter (Beyond Fabric Name)
GSM (Fabric Weight)
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120–150 GSM: Ultra-light, best for hot weather and speed.
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150–180 GSM: Balanced—most popular for multi-climate leagues.
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180–220 GSM: Heavier handfeel, more structure, colder nights.
Denier & Yarn Quality
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Lower denier microfibers = softer hand + better drape.
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Ask for anti-pilling and colorfastness test results to avoid fuzzing and wash fade.
Stretch & Recovery
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2–8% elastane gives mobility for swings, stretches, and slides.
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Check recovery so jerseys don’t bag out after innings.
Moisture Management & Finishes
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Look for moisture-wicking, quick-dry, anti-odor, and optional UV protection finishes (UPF 30+ or 50+ for daytime tournaments).
Printing Methods: Match Fabric to Art
Sublimation (Best with Polyester)
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Why choose it: Deep, permanent color; won’t crack or peel; perfect for all-over graphics, gradients, and complex patterns.
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When to use: Custom baseball jersey with full-body graphics, sponsor panels, and sharp numbers.
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Fabric pairing: Polyester mesh, interlock, bird’s-eye, microfiber.
Screen Printing
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Why choose it: Bold, opaque inks; economical at higher quantities.
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When to use: Solid logos and numbers; spot-color designs.
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Fabric pairing: Polyester and cotton. Add blocker underbase on poly to prevent dye migration.
Heat Transfer (Vinyl/DTF)
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Why choose it: Great for names/numbers; fast personalization; low setup.
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When to use: Small bulk order runs with variable player info.
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Fabric pairing: Most poly or cotton; mind wash-care for longevity.
Embroidery & Appliqué
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Why choose it: Premium texture and depth.
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When to use: Crests, captain patches, limited areas due to weight.
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Fabric pairing: Interlock or piqué for structure under stitchwork.
Construction Details That Elevate a Jersey
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Stitching: Double-needle hems and flatlock seams reduce chafing.
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Panels: Raglan sleeves for range of motion; mesh side panels for cooling.
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Collars: V-neck or split-V for airflow; reinforced placket on button-front baseball tops.
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Reinforcements: Bar-tacks at stress points (shoulders, hem, name/number zones).
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Fit: Classic, athletic, or relaxed. Clarify length and chest ease for your roster.
Climate & Use-Case Playbook
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Hot & Humid: Mesh or microfiber with aggressive moisture-wicking.
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Mild/All-Season: Bird’s-eye piqué or interlock polyester.
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Cool Evenings: Heavier interlock (180–200 GSM) or a layering strategy.
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Tournament Weekends: Quick-dry polyester to wash overnight and wear next day.
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Fan Merch: Cotton-rich blends for comfort; reserve performance poly for on-field.
Fit, Sizing & Inclusivity in Bulk Orders
When you place a bulk order, request a full size-run and clarify fit type. Include youth/women’s cuts if needed (or offer unisex with detailed measurements). For custom baseball jersey rosters, collect chest, body length, and preferred ease; share a size chart early to avoid exchanges mid-season.
Care Instructions That Protect Your Investment
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Cold wash, inside-out.
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No bleach or fabric softener (they can reduce wicking performance).
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Low-heat tumble or hang dry.
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Avoid high-heat ironing directly on prints; use a press cloth if necessary.
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Wash like colors together to prevent dye transfer.
Budgeting & Lead Times (What to Expect)
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Fabric cost: Mesh is often the most economical; interlock and microfiber can price higher.
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Decoration: Sublimation has higher fabric/print setup but lower per-unit complexity for full-cover art. Screen print is efficient at higher volumes; heat transfer is flexible for variable names.
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Sampling: Always approve a pre-production sample to validate colorfastness, fit, and logo placement before green-lighting your bulk order.
Common Questions (Quick Answers)
What’s the best fabric for a baseball jersey?
For on-field use, polyester interlock or mesh with moisture-wicking is ideal. Interlock offers a premium look; mesh maximizes airflow.
Will sublimation fade?
On polyester, sublimation is embedded in the fibers and resists cracking or peeling. Use mild detergents and avoid high heat for longest life.
How heavy should a jersey be?
Most teams choose 150–180 GSM. Go lighter for heat/humidity, heavier for structure or evening games.
Can we do eco-friendly jerseys?
Yes. Recycled polyester (rPET) delivers performance plus sustainability—great for leagues promoting green initiatives.
What if we want names and numbers per player?
Combine decoration methods: sublimation for the base design + heat-applied names/numbers or incorporate everything into the sublimated layout.
Your Game Plan for the Perfect Custom Jersey
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Define the use case: game, practice, or fanwear.
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Pick the fabric: mesh for airflow, interlock for polish, piqué for balance, microfiber for stretch.
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Lock specs: GSM range, moisture-wicking, anti-pilling, UV, and size run.
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Match print to art: sublimation for complex all-overs; screen/HTV for spot graphics.
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Test & approve: sample fit, color, and print durability before placing the bulk order.
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Plan care & reorders: publish wash instructions; keep source files ready for reprints.
How Jersey Crafted Can Help
At Jersey Crafted, we build custom baseball jersey programs around your sport, climate, and budget. We’ll help you select the ideal fabric (mesh, bird’s-eye piqué, interlock, microfiber, or recycled poly), choose the right decoration method, and size your roster accurately. Need league-wide uniforms or event kits? Ask about bundled pricing and fast turnaround for your next bulk order.
Want design to pop as much as the fabric performs? Pair breathable interlock or mesh with bold, high-visibility artwork and oversized numbers for instant field readability and fan appeal. For creative layout ideas and logo scale tips, see “Big Logos, Bigger Impact” on Jersey Crafted: Big Logos, Bigger Impact: Custom Sports Jerseys That Speak for You for additional practical guidance.
